UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN OPTIMIZATION OF DRAIN COVER USING FINITE
ELEMENT ANALYSYS
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) (Hons.)
by
NAQISYAH BINTI NAZER B 051110256
910205 – 02 - 5694
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design) (Hons.). The member of the supervisory is as follow:
………
DECLARATION
I hereby, declared this report entitled “Design Optimization of Drain Cover using Finite Element Analysis” is the results of my own research except as cited in
references.
Signature : ………
Author’s Name : NAQISYAH BINTI NAZER
i
ABSTRAK
ii
ABSTRACT
iii
DEDICATION
This report is dedicated to my beloved parents, brothers and sisters for their endless
love, support and encouragement. I also dedicate this work to my supervisor and
friends who have supported me throughout the process.in completing this thesis. I
will always appreciate all they have done.
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ACKNOWLEDGEMENT
Bismillahirrahmanirrahim,
Alhamdulillah. I would like to express my thankfulness to Allah S.W.T because I manage to finish this Final Year Project 1 on time. With full of His merciful, now I am writing this report of this project. This Final Year project was prepared for Faculty of Manufacturing Engineering University Teknikal Malaysia Melaka (UTeM) for student in fourth year to complete the undergraduate program that leads to the degree of Bachelor of Engineering in Manufacturing.
Secondly I would like to state my gratitude to my supervisor, En. Abdul Halim Hakim Bin Abdul Aziz for his assistance and guidance in producing this report and giving me his constructive comments, guidance, patience and encourage until the completion of this report. Besides that, I would like to express my deepest thankfulness and appreciation to my parents and friends for their continuous supports and advices in complete the report.
I hope that this project report will fulfill the conditions as requested in Final Year Project in UTeM.
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TABLE OF CONTENTS
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Contents v
List of Tables ix
List of Figures xi
List of Abbreviations, Symbols and Nomenclatures x
CHAPTER 1: INTRODUCTION 1.1 Background of Project 1
1.2 Finite Element Analysis 2
1.3 Problem Statement 3
1.4 Objective 3
1.5 Scope 4
CHAPTER 2:LITERATURE REVIEW 2.1 Introduction 5
2.2 What is Drain Cover? 5
2.2.1 Specification of Structural steel grating weight 7
2.3 Material of Drain Cover 12
vi
2.4 FEA Solution and Output Data 19
2.5 The Average of Vehicle Weight 21
2.6 Height and Weight Table
2.6.1 Females 22
2.6.2 Males 23
2.7 Computer Aided Design (CAD) 24
2.7.1 Element of CAD System 25
2.7.2 CAD Software (Solidworks) 26 2.7.3 3D Computer Graphics 26 2.8 Finite Element Tool 27
2.8.1 History of FEA 28
2.8.2 How does FEA works? 29
2.8.3 Finite Element Analysis 30
2.8.4 Processing 30
2.8.5 Analysis 31
2.8.6 Visualization 31
2.8.7 Application of FEA to Mechanical Engineering Industry 31 2.8.8 Computer Aided Design and Finite Element Analysis in Industry 32 2.8.9 The Advantage of Finite Element Analysis (FEA) 33
CHAPTER 3:METHODOLOGY
3.1 Introduction 35
3.2 Project Planning 35
3.3 Project Flow Chart 36
3.4 Phase of Methodology
3.4.1 Planning Phase 38
3.4.2 Design Phase 39
3.4.3 Analyze Phase 39
3.4.4 Redesign and Optimize Design Analysis Phase 39
vii
3.5.1 Design 1 40
3.5.2 Design 2 41
3.5.3 Design 3 41
3.5.4 Design 4 42
3.5.5 Design 5 42
3.5.6 Design 6 43
CHAPTER 4: RESULTS AND DISCUSSION
4.1 Introduction 44
4.2 Results and Discussion 45
4.2.1 Analysis Design 1 45
4.2.2 Analysis Design 2 47
4.2.3 Analysis Design 3 49
4.2.4 Analysis Design 4 51
4.2.5 Analysis Design 5 53
4.2.6 Analysis Design 6 55
4.3 Benchmark Data Analysis for New Design 57 4.4 Redesign and Optimization Design using FEA 58
4.4.1 New Design 58
4.4.1.1 Analysis of New Design 59
4.4.2 Redesign 1 62
4.4.2.1 Analysis Redesign 1 63
4.4.3 Redesign 2 65
4.4.3.1 Analysis Redesign 2 66
4.4.4 Redesign 3 69
4.4.4.1 Analysis Redesign 3 69
4.4.5 Redesign 4 72
4.4.5.1 Analysis Redesign 4 72
4.4.6 Redesign 5 75
4.4.6.1 Analysis Redesign 5 75
viii
4.4.7.1 Analysis Final Design 79
CHAPTER 5 : CONCLUSION AND RECOMMENDATION
5.1 Conclusion 83
5.2 Recommendation 84
REFERENCES 85
ix
LIST OF TABLES
2.1 Size of Pitch Bar 8
2.2 Composite Composition 15
2.3 Mechanical Properties of the Composite 15
2.4 Flexural properties for SW and CW 16
2.5 Tensile Properties of waste wood fibre reinforced epoxy composites 17
2.6 sawdust Material Mechanical Properties 18
2.7 Sawdust Material Physical Properties 18
2.8 Sawdust Material Thermal Properties 19
2.9 Sawdust Descriptive Properties 19
2.10 Table of Load 22
2.11 Height and Weight f Females Citizen 23
2.12 Height and Weight of Males Citizen 24
4.1 Details of Design 1 46
4.2 Data Analysis of Design 1 46
4.3 Details of Design 2 48
4.4 Data Analysis of Design 2 48
4.5 Details of Design 3 50
4.6 Data Analysis of Design 3 50
4.7 Details of Design 4 52
4.8 Data Analysis of Design 4 52
4.9 Details of Design 5 54
4.10 Data Analysis of Design 5 54
4.11 Details of Design 6 56
4.12 Data Analysis of Design 6 56
4.13 VON Mises Stress value from 6’s different conceptual designs 57
4.14 Resultant Displacement value from 6’s different conceptual designs 57
4.15 Benchmark Result Analysis for New Drain Cover Design 58
4.16 Details of New Design 61
x 4.18 Comparison between the Benchmark Guideline and New Design 62 4.19 Details of Redesign 1 64 4.20 Data Analysis of Redesign 1 64 4.21 Comparison between Benchmark Guideline and Redesign 1 Analysis Data 65
4.22 Details of Redesign 2 68
4.23 Data Analysis for Redesign 2 68
4.24 Comparison between the Benchmark Guideline and Redesign 2 68
4.25 Details of Redesign 3 71
4.26 Data Analysis of Redesign 3 71
4.27 The comparison between Benchmark Guideline and Redesign 3 71
4.28 Details of Redesign 4 74
4.29 Data Analysis of Redesign 4 74
4.30 The comparison between Benchmark Guideline and Redesign 4 74
4.31 Details of Redesign 5 77
4.32 Data Analysis of Redesign 5 77
4.33 The comparison between Benchmark Guideline and Redesign 5 77
4.34 Details of Final Design 80
4.35 Data Analysis of Final Design 81
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LIST OF FIGURES
2.1 Structural steel grating weight for tubular type outdoor drain cover 6
2.2 Product Structure 8
2.3 Type of Bar 9
2.4 Detail structure of grating drain cover 10
2.5 Size of the Grating 11
2.6 Type of Chip wood (a),(b),(c) 14
2.7 Type of Sawdust (d),( e ), (f) 14
2.8 Degree of freedoms at a simple beam element 20
2.9 The stiffness matrix of a beam element that lies along the x-axis 20
2.10 Example process of Finite Element Analysis 27
3.1 Project Planning Flow Chart 37
3.2 Flow Chart for PSM 1 38
3.3 Isometric view of Design 1 40
3.4 Isometric view of Design 2 41
3.5 Isometric View of Design 3 41
3.6 Isometric view of Design 4 42
3.7 Isometric view of Design 5 42
3.8 Isometric view of Design 6 43
4.1 Design 1 Analysis Restrain 45
4.2 Design 1 Distributed Load 45
4.3 Design 1 Stress Distribution 46
4.4 Design 1 Displacement Distribution 46
4.5 Design 2 Analysis Restrain 47
4.6 Design 2 Distributed Load 47
4.7 Design 2 Stress Distribution 48
4.8 Design 2 Displacement Distribution 48
4.9 Design 3 Analysis Restrain 49
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4.11 Design 3 Stress Distribution 50
4.12 Design 3 Displacement Distribution 50
4.13 Design 4 Analysis Restrain 51
4.14 Design 4 Distributed Load 51
4.15 Design 4 Stress Distribution 52
4.16 Design 4 Displacement Distribution 52
4.17 Design 5 Analysis Restrain 53
4.18 Design 5 Distributed Load 53
4.19 Design5 Stress Distribution 54
4.20 Design 5 Displacement Distribution 54
4.21 Design 6 Analysis Restrain 55
4.22 Design 6 Distributed Load 55
4.23 Design 6 Stress Distribution 56
4.24 Design 6 Displacement Distribution 56
4.25 Isometric view of Drain Cover New Design 59
4.26 New Design Analysis Restrain 59
4.27 New Design Distributed Load 60
4.28 New Design Stress Distribution 60
4.29 New Design Displacement Distribution 61
4.30 Isometric view of Redesign 1 63
4.31 Redesign 1 Analysis Restrain 63
4.32 Redesign 1 Distributed Load 63
4.33 Redesign 1 Stress Distribution 64
4.34 Redesign 1 Displacement Distribution 64
4.35 Isometric View of Redesign 2 66
4.36 Redesign 2 Analysis Restrain 66
4.37 Redesign 2 Distributed Load 67
4.38 Redesign 2 Stress Distribution 67
4.39 Redesign 2 Displacement Distribution 67
4.40 Isometric View of Redesign 3 69
4.41 Redesign 3 Analysis Restrain 69
4.42 Redesign 3 Distributed Load 70
xiii
4.44 Redesign 3 Displacement Distribution 70
4.45 Isometric View of Redesign 4 72
4.46 Redesign 4 Analysis Restrain 72
4.47 Redesign 4 Distributed Load 73
4.48 Redesign 4 Stress Distribution 73
4.49 Redesign 4 Displacement Distribution 73
4.50 Isometric View of Redesign 5 75
4.51 Redesign 5 Analysis Restrain 75
4.52 Redesign 5 Distributed Load 76
4.53 Redesign 5 Stress Distribution 76
4.54 Redesign 5 Displacement Distribution 76
4.55 Isometric View of Final Design 78
4.56 Final Design Analysis Retstrain 79
4.57 Final Design Distributed Load 79
4.58 Final Design Stress Distribution 80
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LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
CAD - Computer Aided Design CAE - Computer Aided Engineering CW - Chip wood
Cm - Centi Meter C1 - Composite 1 C2 - Composite 2 C3 - Composite 3
FEA - Finite Element Analysis FEM - Finite Element Method GPa - Giga Pascal
J - Joule
kg - Kilogram
kN - kilo Newton
kJ/m^2 - kiloJoule per meter square mm - Mili Meter
Min - Minimum Max - Maximum MPa - Mega Pascal
N - Newton
CHAPTER 1
INTRODUCTION
This chapter will explain about the background of the project study, problem statement, the objective of the study and also the scope of the project study.
1.1 Project Background
Then optimize the Drain cover frame design by redesign Drain cover frame until get the best result of analysis. This project tries to propose the best design and analysis of Drain cover frame. The optimization to increase quality, reduce product cost and full fill the customer satisfaction. For this project CAD tools as tools to design drain cover and FEA tools for the analysis. For this project software to be used are SOLIDWORKS as CAD software and NASTRAN PATRAN software as analysis software.
1.2 Finite Element Analysis
1.3 Problem Statement
The issue of the innovation of this product is stated according to the massive loss of steel drain cover since early 1990’s. According to the police report, the thieving activities of the drain cover are influenced by value of steel that increasing gradually year by year. Until today, this unhealthy activity is still out of control by the authority even though some city council starts to restrict their drain cover with bolt to the concrete cement. Hence, the problem of the drain cover loss do affected the safety of citizen. There are many cases of citizen (mostly affected the elders and children) fell down into a drain caused by the disappearance of the drain cover, and most of the cases are caused by the loss of the drain cover mostly at their residential area and some of it ashamedly happen at public area like city area. The seriousness of this incident sometimes have been neglect by some party because of this case of accident is still minor, but once it’s happen when people start to blame the authority and city council. So, the better way to avoiding this consequences from happening again and again is by changing the existing material of drain cover which is steel with the sawdust material which has less market value compared to the steel. Hence, it is a better way on how to handle the dumped waste more appropriately than being throw it as a rubbish. Moreover, the number of rubbish can be reduced plus can balance our lovely natural environment.
1.4 Objectives
To redesign a new concept of drain cover from the existing drain cover that can decrease the drain pollution.
1.5 Scope of Project
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Literature review includes study and research of published material like journals, thesis, case studies, technical document, book and online library. Generally, the purpose of their view is to analyze critically a segment of a published body of knowledge through summary, classification, approach used in their project, and any technique that used in their study, review of literature and theoretical articles. This chapter will describe topics that related of Computer Aided Design (CAD), design, conceptual design, Optimization, Finite Element Analysis (FEA), Design Process and other relevant topic for this project. These chapters to carry out any approach that can use in drain cover frame design and analysis using Finite Element Analysis method and carry out current product design.
2.2 What is Drain Cover?
A fitting waste will spare your property from water harm by keeping it dry even in the heaviest of downpour storms. The way to a legitimate seepage framework is a useful waste setup utilizing the right kind of building materials that will help flow water far from your property and not endure water harm simultaneously.
required. In the last case, there is a conspicuous wellbeing issues, on the grounds that numerous individuals don’t have experience more than the head of the water over the channel when touching a drain. For an example, in a previous case, a lifeguard went to the base of a pool to recover something at the bottom of the pool and his hand got stuck on account of the additional weight and extra pressure from the pump. At the point when there is a recirculating pump, the danger of the suction comprises of the head of the water, in addition to the suction of the pump. As a consequence of this suction capture or Duct Entanglement, there had an accident lead to fatalities have occurred around the drains. In these circumstances, a share of the body, hair, or apparel may get to be stuck against the channel will be bringing about suffocating and may get to be difficult to discharged away. When an allotment of the channel opening is blocked, the drain suction will increase rapidly by having two channels or a bigger channel inlet permits an interchange suction ways for the pump. It there has a rapid increase in the suction is detected, the safety devices installed in the swimming pool are accessible to consequently turn off an operating working pump. The children should be taught not to deliberately touch or attempt to block the components of a swimming pool recirculation system while the alarm may be in counterproductive state.
Figure 2.1 : Structural steel grating weight for tubular type outdoor drain cover (Source : <http://www.alibaba.com/product-detail/Structural-steel-grating-weight-for-tubular_136833162.html>
2.2.1 Specifications of structural steel grating weight
This guideline were stated by one of the steel and gratings manufacturer manufacturers that established in 1993 by Tohoku Okajima.
1. Reasonable cost and have the Japanese quality. 2. Good rub resistance and corrosive resistance. 3. Strong heavy-loading ability.
4. Safety in use.
Numerous homes have an outside concrete, solid or like material deck adjoining the house. Normally, a screen walled in area is introduced above and around the deck to give an outside stimulation range that is protected from irritations, for an example mosquitoes, flies and etc. Regularly, the surface of the deck is higher than the encompassing the ground surface which is generally grass or earth. The edge of the structure of the screen incorporates a base rail or track which mounts to the top of the surface of the deck. Therefore, it surrounds the ground surface. The base rails of the screen fenced in the region frame structure is pretty nearly 1” to 11/2” in tallness and when mounted to the deck surfaces. The frames structures will raised the lip which keeps the water from flowing out of the deck surfaces and surrounded the ground surfaces.
In many cases, the decks are slanted to regulate the water towards the corners. The base rail will raised the lip and keeping the water from streaming off from the deck surface, causes the rain water, pool water, and so forth to gather in the corners. In a short time, the determined of the gathering of the standing water causes the buildup, mold, and staining of the deck.
